G4XZ Valves
Sleeveline® Plug Valves
Installation
Operation
Maintenance
VAIOM000321-00(EN)
Original Instructions
These instructions must be read prior to installing, operating, and
maintaining this equipment.
G4XZ Sleeveline® Plug Valve User Instructions
Copyright
All rights reserved. No part of these instructions may be reproduced, stored in a retrieval
system or transmitted in any form or by any means without prior permission of Flowserve
Corporation.
Document Version
Initial Release, 25-MAR-2022
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G4XZ Sleeveline® Plug Valve User Instructions
CONTENTS
1
General Information ........................................................................................................................ 5
1.1
Scope of manual ..........................................................................................................................................5
1.2
Disclaimer ......................................................................................................................................................5
1.3
Certification instruction ................................................................................................................................5
1.4
Units ................................................................................................................................................................6
2
Safety Information ........................................................................................................................... 6
2.1
Intended use .................................................................................................................................................6
2.2
Safety symbols and description ..................................................................................................................6
2.3
General hazard sources ..............................................................................................................................7
2.4
Qualified personnel and targeted group .................................................................................................8
2.5
Industrial health and safety measures .......................................................................................................8
2.6
Potential explosive areas.............................................................................................................................8
2.7
Protective equipment ..................................................................................................................................9
3
Product Description ......................................................................................................................... 9
3.1
General product description ......................................................................................................................9
3.2
Design ............................................................................................................................................................9
3.3
Scope of delivery .........................................................................................................................................9
3.4
Function description.....................................................................................................................................9
3.5
Connections............................................................................................................................................. 100
4
Packaging, Transportation and Storage ................................................................................... 100
4.1
Consignment receipt .............................................................................................................................. 100
4.2
Storage ..................................................................................................................................................... 111
5
Installation .................................................................................................................................... 122
5.1
Inspection and preparation ................................................................................................................... 122
5.2
Installation ................................................................................................................................................ 133
6
Commissioning ............................................................................................................................ 144
7
Operation ..................................................................................................................................... 144
7.1
Preparatory activities .............................................................................................................................. 144
7.2
Start-up ....................................................................................................................................................... 14
7.3
Normal operation .................................................................................................................................... 155
8
8.1
Maintenance ............................................................................................................................... 155
8.2
Schedule..................................................................................................................................................... 15
Adjustment…………………………………………………………………………………………………………15
8.3
Special tools………………………………………………………………………………………………………..16
8.4
Required replacement parts for maintenance ................................................................................... 166
8.5
Disassembly .............................................................................................................................................. 166
8.6
Spare part Stocking Recommendation………………………………………………………….……………18
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G4XZ Sleeveline® Plug Valve User Instructions
8.7
Reassembly : Plug Assembly .................................................................................................................. 199
8.8
Reassembly: Sleeve Installation ................................................................ Error! Bookmark not defined.9
8.9
Reassembly: Remaining Components………………………………………………………………………………….………………….21
8.10
Post Maintenance Inspection .................................................................................................................. 22
9
Troubleshooting Guide ................................................................................................................. 22
10 Returns and Disposal ..................................................................................................................... 24
10.1
Returns ........................................................................................................................................................ 24
10.2
Disposal and recycling ............................................................................................................................. 24
Annex A: Declaration of Conformity .................................................................................................. 26
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G4XZ Sleeveline® Plug Valve User Instructions
1
General Information
1.1 Scope of manual
These instructions must be kept close to the product’s operating location or directly with
the product.
These instructions must be read prior to installing, operating, using, or maintaining the
equipment in any region worldwide. The equipment must not be put into service until all of the
safe operating conditions noted in the instructions have been met. Failure to comply with the
information provided in the User Instructions is considered to be misuse. Personal injury, product
damage, delay in operation, or product failure caused by misuse are not covered by the
Flowserve warranty.
The following user information covers the Installation, Operation & Maintenance procedure for
DURCO G4X Sleeveline® Plug Valves.
These instructions are intended to familiarize the reader with the product and its permitted use.
Operating the product in compliance with these instruction is important to help ensure reliability
in service and avoid risks. These instructions may not take into account all local regulations;
ensure such regulations are observed by all, including those installing the product. Always
coordinate repair activities with operations personnel, and follow all plant safety requirements
and applicable safety and health legislation.
1.2 Disclaimer
Information in this User Instruction is believed to be complete and reliable. In spite of all
Flowserve’s efforts to provide comprehensive information and instructions, sound engineering
and safety practices should always be used. Please consult with a qualified engineer.
Flowserve manufactures products to applicable International Quality Management System
Standards as certified and audited by external Quality Assurance organizations. Genuine parts
and accessories have been designed, tested, and incorporated into the products to help
ensure continued product quality and performance in use. As Flowserve cannot test parts and
accessories sourced from other vendors the incorrect incorporation of such parts and
accessories may adversely affect the performance and safety features of the product. The
failure to properly select, install, or use authorized Flowserve parts and accessories is considered
to be misuse. Damage or failure caused by misuse is not covered by Flowserve’s warranty. In
addition, any modification of Flowserve products or removal of original components may impair
the safety of these products in use.
1.3 Certification instruction
It is a legal requirement that machinery and equipment put into service within certain regions of
the world shall conform to the Marking Directives applicable to Flowserve products (i.e.
Machinery Directive, Low Voltage Directive, Electromagnetic Compatibility (EMC) Directive,
Pressure Equipment Directive (PED), Equipment for Potentially Explosive Atmospheres (ATEX),
etc.).
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G4XZ Sleeveline® Plug Valve User Instructions
Note: Certificates defined in the Contract requirements are provided with these instructions
where applicable. Examples of the certificates can be found in the Annex of this document. If
required, copies of other certificates sent separately to the Purchaser should be obtained from
the Purchaser for retention with this User Instruction.
1.4 Units
This document contains measurements in both the metric and English standard unit systems.
2
Safety Information
2.1 Intended use
The product/system must not be operated beyond the parameters specified for the
application. If there is any doubt as to the suitability of the product/system for the application
intended, contact Flowserve for advice, quoting the serial number.
•
Installing, operating, or maintaining the product/system in any way that is not covered in
this User Instruction could cause death, serious personal injury, or damage to the
equipment. This includes any modification to the product/system or use of the parts not
provided by Flowserve.
•
Only operate the product/system when it has successful passed all inspection
acceptance criteria
•
Do not operate the product/system in a partially assembled condition.
•
If the conditions of service on the customer’s purchase order change (i.e. pumping fluid,
temperature, or duty conditions) it is requested that the user seeks written agreement
from Flowserve before start up.
•
Observe equipment labels, such as arrows designating the direction of rotation, warning
signs, etc., and keep them in a legible condition. Replace any damaged and/or illegible
labels immediately.
2.2 Safety symbols and description
This User Instruction contains specific safety markings where non-observance of an instruction
would cause a hazard. The specific safety markings are:
Table 1: Definition of safety symbols and markings
Symbol
Description
DANGER
This symbol indicates a hazardous situation which, if not
avoided, will result in death or serious injury
WARNING
This symbol indicates a hazardous situation which, if not
avoided, could result in death or serious injury
CAUTION
This symbol indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury
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G4XZ Sleeveline® Plug Valve User Instructions
Safety Instruction
This symbol indicates specific safety-related instruction or
procedures
NOTICE
This symbol is used to address practices not related to
physical injury
This is the safety alert symbol. It is used to alert you to
potential physical injury hazards. Obey all safety messages
that follow this symbol to avoid possible injury or death.
Table 2: Additional symbols
Symbol
Description
ELECTRICAL HAZARD
This symbol indicates electrical safety instructions where
non-compliance would affect personal safety and could
result in loss of life
TOXIC HAZARD
This symbol indicates “hazardous substances and toxic fluid”
safety instructions where non-compliance would affect
personal safety and would damage the equipment or
property
ATEX EXPLOSION PROTECTION
This symbol indicates explosive atmosphere marking
according to ATEX. It is used in safety instructions where noncompliance in the hazardous area would cause the risk of
an explosion
2.3 General hazard sources
2.3.1
Mechanical Hazards
a) Lifting limits and guidelines
Note: The load values mentioned in this section are Flowserve recommendations only. All lifting
must be done in compliance with site safety protocol, local regulations, and related industry
standards.
Many precision parts have sharp corners which require appropriate personal protective
equipment during handling. Prior to any attempt to lift an item, employees must first determine
the approximate weight and stability of the load.
•
Large, unstable, or awkward loads should always be handled with the assistance of
additional personnel or appropriate mechanical means.
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G4XZ Sleeveline® Plug Valve User Instructions
•
Loads in excess of 23kg (50 lb.) should only be lifted by appropriate mechanical
means and in accordance with current local legislation or with the assistance of
additional personnel.
•
Lifting items less than 23kg (50 lb.) may be prohibited without assistance if the lift is
repetitive and/or awkward (i.e., away from the body, above the shoulders or below
the knees) thus placing excessive stress on the personnel.
•
Repetitive lifting of any kind should be evaluated as part of a documented end-user
safety program.
•
Do not stand near the valve when it is lifted from ground. Keep some gap.
•
Do not use bonnet bolting or pressure controlling parts to lift the valves.
•
Do not vibration / Hammer stem and bonnet bolting while installing the valve.
2.4 Qualified personnel and targeted group
All personnel involved in the operation, installation and maintenance of the unit must be
qualified to carry out the work involved. If the personnel in question does not already possess the
necessary knowledge and skill, appropriate training and instruction must be provided. If required
the operator may commission the manufacturer / supplier to provide applicable training.
Always co-ordinate repair activities with operation and health and safety personnel, and follow
all plant safety requirements and applicable safety and health laws and regulations.
2.5 Industrial health and safety measures
Follow industry safety standards including the use of appropriate equipment in required areas.
2.6 Potential explosive areas
Measures are required to:
•
Avoid excess temperature
•
Prevent build-up of explosive mixtures
•
Prevent the generation of sparks
•
Prevent leakages
•
Maintain the pump to avoid hazard
All instructions for equipment installed in potentially explosive atmospheres must be followed to
help ensure explosion protection. For ATEX, both electrical and non-electrical equipment must
meet the requirements of the European Explosion Protection Directive 2014/34/EU. Always
observe the regional legal Ex requirements, e.g. Ex electrical items outside the EU may be
required certified to other than ATEX e.g. IECEx, UL.
Use equipment only in the zone for which it is appropriate. Always check that all
equipment is suitably rated and/or certified for the classification of the specific atmosphere in
which they are to be installed.
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G4XZ Sleeveline® Plug Valve User Instructions
2.7 Protective equipment
Wear the necessary protective equipment during the unpacking, installation, operation, and
maintenance of valves.
3
Product Description
3.1 General product description
The Durco G4X product is a non-lubricated sleevelined quarter turn plug valve rated to ASME
Class 150 and Class 300 designs at pressures to 51 bar (740PSI) and temperatures to 232 degrees
C (450 F). The G4X product ranges in size from 1”- 6” offered with a variety of configurations with
options and material alloy and packing.
Figure 3.1: Isometric view of the G4X
3.2 Design
The G4 sleevelined valve is designed pursuant to ASME B16.34 for wall thickness, ASME B16.5 for
flange requirements, ASME B16.25 and B16.11 for butt welds and socket welds and is designed to
meet the pressure and temperature requirements of ASME B16.34.
3.3 Scope of delivery
The exact scope of the delivery is stated in the order documentation.
3.4 Function description
Isolation Valve
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G4XZ Sleeveline® Plug Valve User Instructions
3.5 Connections
Raised Face Flange
Screwed End
But Weld
Socket Weld
Flat Face
Ring Type Joint
Small & Large Groove Flange
Additional Connections upon request
3.5.1
Electrical connections
Applicable if electrical accessories are used. Please refer to those appropriate IOMs
3.5.2
Pneumatic connections
Applicable if pneumatic actuator or other pneumatic accessories are used. A pneumatic
actuator typically requires a ¼ inch air supply of at least 60 psi (bar). Larger actuators will require
a 3/8 inch air supply. Flow boosters will require ½ inch to ¾ inch independent air supply from the
positioner. Limit switches or position indicators may be mounted external to a positioner. Please
refer to those appropriate IOMs
3.5.3
Mechanical connections
Applicable if custom extensions are used. Please refer to those appropriate IOMs
3.5.4
Auxiliary connections
Applicable if custom auxiliary connections are used. Please refer to those appropriate IOMs
4
Packaging, Transportation and Storage
4.1 Consignment receipt
Immediately after receipt of the product/system it must be checked against the
delivery/shipping documents for its completeness and that there has been no damage in
transportation. Any shortage and/or damage must be reported immediately to Flowserve and
must be received in writing within one month of receipt of the equipment. Later claims cannot
be accepted.
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G4XZ Sleeveline® Plug Valve User Instructions
4.2 Storage
4.2.1
Short Term Storage Instructions/Recommendation
4.2.1.1 The following instructions are recommended where valve storage is intended for valves that are
to be stored on site prior to installation up to six months. Extended storage beyond six months
may require additional instructions depending on the location.
4.2.1.2 During on-site storage, all valves with special cleaning and/or preparation, should be kept in
original special packaging as shipped from Flowserve for protection from contamination.
4.2.1.3 Valves should be stored indoors, above ground and protected from harsh environments.
4.2.1.4 Always store valves in a clean dry location and away from dust, dirt, debris, corrosive materials
and wet areas. Water must not be allowed to enter actuated pneumatic cylinder or electrical
connections.
4.2.1.5 Keep the valves in a cool location and out of exposure to direct sunlight and excessive heat.
4.2.1.6 Ball and plug valves should be stored in the open position.
4.2.1.7 Actuated valves should be stored in a horizontal position.
4.2.2
4.2.2.1
4.2.2.2
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.3.4
4.2.4
4.2.4.1
4.2.4.2
Long Term Storage Instructions/Recommendation
In addition to short term instructions the following instructions are recommended where valve
storage is intended for valves that are to be stored on site for periods exceeding six months.
Valves should be stored indoors, above ground and protected from harsh environments
where temperature exceeds minimum of -20 degrees F or maximum of 180 degrees F to
prevent seal compression set.
Recommended six-month maintenance for Long Term Storage
Visually inspect valve assembly ensuring valve original special packing as shipped from
Flowserve is in its original condition.
Cycle manual valve three complete cycles.
Cycle automated valves using dry instrument air or dry Nitrogen.
Replace desiccants and reseal protective packaging.
Elastomers/Soft Goods
Per the manufacturers, “All mechanisms by which rubber deteriorates with time are
attributed to environmental conditions. Therefore, storage conditions, not time, determine
the life of rubber seals.”
To preserve the physical properties of the components containing elastomers widely used in
our valves, the following storage conditions must be adhered to:
· Ambient temperatures not to exceed 120 degrees F.
· Exclusion of all significant contaminants and foreign materials.
· Exclusion of direct sunlight.
· Exclusion of significant radiation.
· Exclusion of significant ozone.
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G4XZ Sleeveline® Plug Valve User Instructions
4.2.5
Age control
4.2.5.1
4.2.5.2
4.2.5.3
It is recommended that users refer to the IOM for recommended adjustments to be
performed prior to using shelf stored valves that fall within the short and long term conditions
specified in this procedure.
Fasteners and packing nut torque checks are recommended to ensure fasteners and nuts
remain per IOM published values prior to using stored valves.
For most commonly used elastomers used on Flowserve Cookeville Valves see Table below.
Description
Source
Projected shelf life
RUBBER
FLS
3 YRS
ETHYLENE PROPYLENE (EPDM)
FLS
6 YRS
VITON FLUORO-ELASTOMER
FLS
6 YRS
Butadiene Acrylonitrile (such as Buna N)
FLS
10 YRS
PFA
DuPont Co.
Unlimited
PTFE
DuPont Co.
Unlimited
Age Controls for different Elastomers
5
Installation
5.1 Inspection and preparation
5.1.1
Material Selection
Selecting the proper fastener material is the ultimate responsibility of the customer because
the supplier does not typically know in what service the valves will be used or what elements
may be present in the environment. Flowserve normally supplies B7 (carbon steel) for ductile
cast iron and carbon steel valves. For stainless steel and high alloy valves, B8 (stainless steel)
fasteners are supplied as standard. All fasteners used must have a minimum yield strength of
40 000 PSI, a minimum elongation of 12% and be compatible with the process fluid.
Determining compatibility to the process fluid goes beyond a material being resistant to
general corrosion because the more important consideration is a material’s resistance to
stress corrosion cracking. Depending on the service, it may make sense to use B7 fasteners
on high alloy valves. One such service would be marine environments because of stainless
steel’s susceptibility to stress corrosion cracking in chloride environments. Another key aspect
of fasteners is frequent visual inspection. Because of the common practice of using steel
fasteners rather than stainless steel to avoid chloride stress corrosion cracking, visual
inspection is recommended to monitor the general corrosion of these fasteners. If jacketing
or insulation is used on a valve, it must be periodically removed for visual inspection of the
fasteners. If you wish assistance in determining the proper fasteners to use, please refer to the
attached chart.
5.1.2
Design & Type
The Flowserve valve design standards adopt ASME B18.2.1 (1996) as the standard for fastener
type and design. This national standard requires that finished hex “head” cap screws be used
when the head of the fastener is turned. A finished hex “head” cap screw and a heavy hex cap
screw have a bearing surface under the head to minimize frictional resistance during tightening.
They also comply to qualified body diameters and fully formed head dimensions. Cookeville
Valve Operation policy is to use finished hex “head” and heavy hex “head” cap screws for all
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G4XZ Sleeveline® Plug Valve User Instructions
pressure retaining fasteners. This includes top caps, packing adjusters, plug adjusters, bottom
caps, body halves or other pressure retaining components. Compliance is made with NSI B18.2.2
(1987), Square and Hex Nuts, when studs and heavy hex nuts are required. Additional
information on these items may be obtained from the Flowserve Corporation, Cookeville Valve
Operation, Cookeville, Tennessee.
5.2 Installation
5.2.1
Flanged End Valves:
Installation of Flowserve flanged valves is best accomplished by locating valves in pipeline
flanges, assuring all corrosion and foreign materials are removed from pipe flange, and then
center gaskets with the valve flanges. Fastener or taper pins should be used to align holes and
locate gaskets. Fasteners should be tightened to the corresponding valve and fastener size.
5.2.2
Weld End Valves:
Flowserve recommends using only qualified welding procedures and personal for weld
installation of G4X valves. The following precautions should be observed:
1. The valve should be inspected prior to welding to assure that no foreign materials obstruct
the flow passageway and that the weld preparation is free of corrosion and physical
damage.
2. The valve should be in the open position while being welded. Open position is when the flats
on the plug stem are parallel with the pipeline.
3. The valve body sleeve and diaphragm must not exceed maximum temperatures during
welding. This includes preheats, interpasses, or post weld heat treatments, as applicable.
4. Welding of the G4X valve without disassembly may be accomplished with no damage to
the sleeve and diaphragm. Precautions MUST be taken to cool the valve bowl and monitor
temperature. The temperature of the center or bowl area of the valve must not exceed the
listed temperature for the material. See Table 1.
TABLE 1
TEMPERATURE LIMITATIONS
MATERIAL DESCRIPTION
MAXIMUM
SERVICE
TEMPERATURE
Ultra High Molecular Weight Polyethylene (UMPE)
200°F (93°C)
Tetrafluoroethylene Polymer (PTFE)
400°F (204°C)
Durlon 2 (TFM)
450°F (232°C)
Duriron Durco 82 (DU-82)
275°F (135°C)
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G4XZ Sleeveline® Plug Valve User Instructions
5.2.3
Flow Direction
The G4X is vented to ensure integrity of valve cavity. The Plug is vented and is marked with a V
on the top of the stem as well as the side of the stem.
Flow direction on the valve is indicated with an arrow on the end flange (if applicable).
Unless otherwise ordered, the vent will be arranged upstream when closed, opposite of
indicated Flow direction on the valve.
Flow indicated by Arrow
Vent indicated by V
(plug rotated 180 deg for illustration)
6
Commissioning
6.1 Prior to start-up
Check any auxiliary or accessory connections to ensure integrity of joint.
Check for full stroke by making the appropriate signal change or manual actuation.
Observe position indicator.
The position should rotate 90 degrees in a smooth, rotary fashion.
6.2 After short time operation
Check fasteners to ensure they are tight
Torque reading make be irregular due to use of thread locking compounds
7
Operation
7.1 Preparatory activities
(OPTIONAL: insert any additional preparatory activities required prior to start-up)
7.2 Start-up
(Describe step-by-step instructions for proper start-up the product/system. Include a checklist of
actions to be completed prior to start-up of the product/system. Describe the necessary
information related to the operational environment and awareness of the equipment during
operation to promote proper operation. Detail the meaning of the different application signals
for digital and automated products in this section.)
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G4XZ Sleeveline® Plug Valve User Instructions
7.3 Normal operation
(List the product/system normal operating range, limits, and if applicable, any specific activities
to properly operate the equipment.)
8
Maintenance
8.1 Schedule
Do not attempt any maintenance of these valves while in operation or under pressure. Actuated valve
air and/or electrical power supplies must be locked off and isolated prior to any maintenance work. To
do otherwise may result in significant equipment damage, hazardous material discharge, or serious
personal injury.
Table 3: Maintenance and service interval
No.
Service
Schedule
/ Cycles
Criteria
Action
Inadequate
Good
1
Visual inspection of
valves
Yearly
If gasket leakage
persists or if bolting is
damaged
No action
2
Preventive change
of the packing
Every
18months
Minimum of
once every 18
months
3
Preventive overhaul
of the valve
Every 60
months
Dependent upon result
of the bi-weekly visual
inspection on valve
leakage
Dependent upon result
of the bi-weekly visual
inspection
Remove from
service and
replace body
bolting
immediately
Immediately
change of the
packing
Minimum of
once every 60
months
8.2 Adjustment
1. Top Cap – Top Cap leakage can by eliminated by tightening the top cap bolts in a “crisscross” pattern to the torque values provided in assembly tables. It is important that torque
values fall within given range in order to maintain bolting integrity.
2. Stem - Leakage due to wear of the packing can be eliminated by tightening the packing
adjuster fasteners to the torque values provided in assembly tables.
3. Through line – Through line or in line leakage can be eliminated by tightening the plug
adjuster fasteners in ¼ turn increments. The fasteners must be tightened evenly for maximum
adjustment. To prevent excessive operating torque, the valve should be cycled after each ¼
turn adjustment. If leakage persists after maximum adjustment is reached, the sleeve and
diaphragm will require replacement.
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G4XZ Sleeveline® Plug Valve User Instructions
8.3 Special tools
Diaphragm guide
Calibrated press
Sleeve insertion tooling
8.4 Required replacement parts for maintenance
Packing
Diaphragms (metal and plastic)
Thrust collar assembly
Bolting
O-rings
8.5 Disassembly
Do not attempt any maintenance of these valves while in operation or under pressure.
Actuated valve air and/or electrical power supplies must be locked off and isolated
prior to any maintenance work. To do otherwise may result in significant equipment
damage, hazardous material discharge, or serious personal injury.
Before disassembly, valves must be relieved of process fluid and pressure. In addition, personnel
performing disassembly must be suitably protected and alert for emission of hazardous process
fluid.
8.5.1
Disassembly Instructions
Refer to Figure 8.6 for parts identification. If an actuator or gearbox operates the
valve, alignment marks should be noted to ensure correct orientation when re-assembled. This
may best be accomplished by making matching marks on the plug stem and operator housing.
8.5.1.1
8.5.1.2
8.5.1.3
Remove wrench, stop collar, or gear/actuation.
Gradually loosen adjuster fasteners (Part 12A) – DO NOT REMOVE.
Rotate plug to allow trapped process fluid or material to vent. Plug should exhibit noticeable
movement “up” when freed from sleeve compression.
If there is no upward movement of the plug (Part 2), it will be necessary to devise a
method of lifting the plug upward. This may require removal of the valve operator. This operation
should be undertaken noting the above precautionary measures. Methods of plug removal must
include protective measures on plug stem and plug end.
8.5.1.4
: Do not loosen or remove top cap fasteners when removing an operator.
Remove the operator by unfastening it from the bracket.
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G4XZ Sleeveline® Plug Valve User Instructions
8.5.1.5
Once the plug has lifted, the packing and plug adjuster fasteners can be completely
removed.
8.5.1.6
Gradually loosen but do not remove the top cap fasteners. Rotate plug to completely free it
from sleeve compression.
8.5.1.7
Remove top cap fasteners and top cap from the plug stem.
8.5.1.8
Remove plug assembly from body.
8.5.1.9
Remove packing gland, stem O-rings, thrust collar, packing wedge, and diaphragms from
the plug stem.
8.5.1.10
Inspect sleeve for damage, especially near the top, bottom, and port areas. If wear is
excessive, the sleeve should be replaced.
8.5.1.10.1
To remove the sleeve: Using a large screwdriver and mallet, cut the old sleeve through
one of the port openings, top and bottom.
8.5.1.10.2
Grasp the sleeve with a pair of pliers while twisting and lift the sleeve from the body.
8.5.1.11
Thoroughly clean all valve parts and inspect parts for damage. Look for marred, scratched,
or rough sealing surfaces on the valve plug (Part 2).
Reinstallation of damaged or unclean parts will ruin any replacement seals
installed into the valve.
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G4XZ Sleeveline® Plug Valve User Instructions
8.6 Spare parts stocking recommendation
Recommended spare parts can be purchased as a
kit, and are as follows:
-
Packing
Diaphragms (metal, plastic)
O-rings
Top Cap Gasket
Sleeve
Fasteners
Thrust Collar
Stop Collar Retainer
When ordering spare parts, the following information
should be provided to Flowserve:
a) Product smart code
b) Number of the parts required
The product smart code is provided on nameplate.
To ensure continued satisfactory operation,
replacement parts to the original design
specification should be obtained from Flowserve.
Any change to the original design specification
(modification or use of non-standard part) will
invalidate the product safety certification.
ITEM
1
2
3*
4A *
4B *
4C *
4D *
5
6
8
9
10
11 *
12
12A
12B
14
19
19A*
20 *
21A *
DESCRIPTION
BODY
PLUG
SLEEVE
PACKING
PACKING
DIAPHRAGM
DIAPHRAGM - METAL
PACKING ADJUSTER
PACKING GLAND
PACKING ADJUSTER FASTENER
TOP CAP
TOP CAP FASTENER
THRUST COLLAR ASSEMBLY
PLUG ADJUSTER
PLUG ADJUSTER FASTENER - STUD
PLUG ADJUSTER FASTENER - HEX NUT
BELLEVILLE WASHER
STOP COLLAR - LOCKING
STOP COLLAR RETAINER
TOP CAP GASKET
O-RING
Spare parts denoted by *
Figure 8.6
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G4XZ Sleeveline® Plug Valve User Instructions
8.7 Reassembly: Plug Assembly
Diaphragm Installation
1. Install PFA diaphragm with assistance of G4X diaphragm guide;
install with reverse lip pointing down as shown in Figure 8.7.
2. For fire sealed valves, install an additional metal diaphragm. ID
radius should follow PFA diaphragm downward.
3. Install stem seal over diaphragm(s).
4. Place thrust collar assembly on stem. The tapped holes on the
thrust collar should align with plug ports.
Packing Installation
Figure 8.7
1. For fire sealed, seat graphite packing, one at a time, by applying force using a calibrated
press with a packing ring pusher per the fire sealed packing load values specified in Table 8.7.
Continue until all packing rings have been installed, alternating each split in packing ring 180
degrees from the previous.
2. Install stem O-rings prior to installing packing gland.
3. Place the packing gland over the plug stem and seat against packing.
TABLE 8.7 FIRESEALED PACKING LOAD
VALVE SIZE
LOAD ±5%
(LBS)
0.5”/.75”
1”/1.5”
2”
3”
4”
6”
8N
8”
10N
10”
12N
12/14
1,300
1,900
3,800
6,400
7,900
11,000
11,500
11,500
17,000
17,000
17,000
17,000
8.8 Re-assembly: Sleeve Installation
1. Apply Durco seal 1028B to the inside of the tapered bore in the body and permit to dry
before assembly. RAD-1 material is used for nuclear applications. Each coat should be
allowed to dry completely. Durcoseal should be dry to the touch. NOTE: If a heat gun is used,
the heat must be applied indirectly to prevent cracking.
2. Remove any Durcoseal that is within the radius behind the locking rib.
3. Prior to sleeve installation, all tooling for sleeve installation shall be wiped clean of visible
particles, such as dirt, Durcoseal, etc. before each use. Verify that the surface finish is
acceptable and that there are no nicks, positives, or scratches on the taper.
4. Mount the body in the assembly station.
5. Insert the coining die into the valve body counterbore.
6. Apply a thin coating of silicone or other approved lubricant to the inside taper of the coining
die. Silicone is not required for installation of TFE sleeves.
7. For 1” and larger valves:
a. Align the sleeve in the coining die with the waterway, then rotate the coining die and
sleeve clockwise to position the sleeve in the coining die so that the diagonal
opposite sides of one side of the sleeve port will lock behind the metal lips in the body.
(The other diagonal opposite sides will be locked in after insertion). See Figure 8.8.1.
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G4XZ Sleeveline® Plug Valve User Instructions
Figure 8.8.1
For 3” and larger valves, install sleeve “shoehorns” into the bowl/waterway in order to
guide the sleeve past the lower part of the waterway opening without being
damaged.
b. Push the sleeve using the plunger(s) until the sleeve drops below the top counterbore
lip of the valve body. Control speed at end of travel to avoid sleeve going too far into
bowl.
c. A special locking plug containing retractable or removable arms (see Figure 8.8.2) is
lowered into the body with the arms retracted or removed. The arms are then
extended or installed, and the plug is rotated counterclockwise until the opposite side
port openings in the sleeve are locked behind the body ribs. In the 1”, 1.5”, and 2”
sizes, a bar may be substituted for the locking plug.
Figure 8.8.2
d. Rotate the locking plug back to center, and retract or remove the arms. Remove the
locking plug, and inspect to ensure the sleeve is locked behind all 4 ribs. See Figure
8.8.3. Reinstall and lock again if required.
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G4XZ Sleeveline® Plug Valve User Instructions
Figure 8.8.3
e. Apply a thin film of silicone or other approved lubricant to the sizing plug. Push the
sizing plug into the sleeve until it bottoms against the counterbore of the valve body.
Allow the sizing plug to remain in position for one minute.
8. Remove sizing plug
9. Verify sleeve is locked in place behind all ribs. Trim any excess material which has sheared off
or is over the ribs, taking care not to scratch the sleeve.
8.9 Re-assembly: Remaining Components
1. Place the top cap gasket in the valve body counterbore.
2. Apply a thin, even coat of silicone or other approved lubricant
per on the entire surface of the plug taper.
3. Place the plug assembly into the bowl of the valve in the open
position.
4. Place the top cap over the plug. Verify top cap and body alloys
are both shown on the same side of the valve.
5. Using an arbor press, push down on the top cap until the plug
port is 1/16 above to level with the sleeve port. (see Figure 8.5.1).
6. Hold the load on the valve, as relieving the force will allow metal
diaphragm to radially ripple.
7. Insert each Top Cap Fastener into two oppositely positioned
Belleville washers.
8. Apply a medium strength thread locker (Loctite 242 or
equivalent) to the threads of the top cap bolts. The thread locker
should cover the threads to a distance at least equal to the bolt
diameter.
Figure 8.5.1
9. For HF valves or HF trim valves, studs and nuts should be used in the top cap. Verify alloy
codes or markings on studs and nuts are seen from the top of the valve. High strength thread
locker (Loctite 262 or equivalent) should be used on the threads.
10. FJG4X (full cast jacket) valves, studs and nuts will be used. Verify alloy codes or markings on
studs and nuts are seen from the top of the valve. Medium strength thread locker (Loctite
242 or equivalent) should be used on the threads.
11. Tighten each Top Cap Fastener finger tight. Remove from arbor press.
12. Tighten the fasteners incrementally, from 50%, 80%, and then 100% of the values listed in
Table 8.5. Bolts should be torqued in a criss-cross fashion to ensure even compression from
the bolts.
13. Place plug adjuster over thrust collar. Insert plug adjuster studs into top cap.
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G4XZ Sleeveline® Plug Valve User Instructions
14. Install nuts onto studs and torque to values listed in Table 8.5, while ensuring the adjuster is
kept level with Thrust collar.
15. Place packing adjuster over stem and packing gland. Insert adjuster screws and tighten to
finger tight.
16. Tighten packing adjuster fasteners to Table 8.5.
17. If required, install stop collar (or pointer) and retainer on plug stem.
18. Visually verify the four seal zones of the sleeve by looking for any extrusions.
19. If required, install gearbox with the plug set in the open position and the open position
adjusting screw is locked. Careful attention is required to set the gearbox stop screw at 90°
rotations for the closed position.
Table 8.5: Torque requirements
Valve Size
1”/1.5”
2”
3”
4”
6”
Top Cap (FT-LBS)
25
40
60
100
200
Plug Adjuster (FT-LBS)
8
10
23
45
110
Packing Adjuster (FT-LBS)
4
10
20
30
52
8.10 Post maintenance inspection
LEAK TESTING: Any time a valve has been modified in any manner, including fastener changes, it
should be retested. Normal testing, using gas, should be at 150 PSI for Class 150 and 300 PSI for
Class 300 valves from 1" through 6". It should be noted, however, that this test does not meet the
requirements of ANSI, API or MSS. For test procedures complying with these specifications, refer
to the appropriate published specification.
9
Troubleshooting Guide
Problems
Problem Descriptions
Leakage Through Top
Cap gasket sealing
External
Leakage
Leakage past Stem
packing
Possible Causes
Recommended actions
Body bolting loose
Tighten Top Cap bolting to
recommended torque value.
Body gasket not compressed
as recommended
Tighten Top Cap bolting to
recommended torque value.
Damage in bonnet gasket
Valve repair will be required
Gland bolting loose
Tighten Packing Adjuster bolting
to recommended torque value.
Packing not compressed
Tighten Packing Adjuster bolting
to recommended torque value.
Packing damage
Check application design
parameters against materials of
construction
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G4XZ Sleeveline® Plug Valve User Instructions
Problems
Problem Descriptions
Possible Causes
Recommended actions
Check for alignment of
components, including side
loading and extensions
Check for damage on stem,
inside thrust collar, and inside
Packing Gland
Remove stem packing from Thrust
Collar and replace new stem
packings. Refer disassembly /
reassembly.
Packing extrusion
Packing Adjuster has been
overtightened and the packing is
no longer functional. Valve
Repair required.
Tighten flange bolting using
correct method
Flange gasket
Leakage through
Pipe Line connections
High
Torque
Replace Flange Gasket
Flange serrations
Inspect Flange faces and have
qualified facility re-machining the
serrations.
Welding not full penetration
Have a certified welder repair the
connection.
Welding porosity
Have a certified welder repair the
connection.
Plug is not sealing against
Sleeve
Use Plug Adjusters to improve
sleeve to plug contact
Plug may not be in fully
closed position
Check the orientation of the plug
stem and ensure the flats on the
stem are perpendicular to the
pipeline
Sleeve is potentially
scratched or damaged.
Valve will likely require repair
Large Leakage with
Rough Operation
Plug and sleeve potentially
have build-up or debris
creating rough surfaces.
Valve needs repair and will likely
continue to increase in leakage
Smooth Operation
with significant Torque
Packing Adjustment may be
overtightened
Reducing force on packing is not
advised as this may cause an
external leak. Valve should be
repaired.
Leakage through
welding connection
Internal
Leakage
Past Plug
Check application design
parameters against materials of
construction
Large Leakage with
Smooth Operation
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G4XZ Sleeveline® Plug Valve User Instructions
Problems
Problem Descriptions
Possible Causes
Recommended actions
Plug Adjustment may be
overtightened
A small Reduction of force on
plug adjuster may be made to
see if operation force is reduced;
however, this may cause internal
through leakage.
Plastic components creep
and create a set torque.
Additional force may be required
for initial operation. This is
accounted for in Valve Sizing
Torques. If the value is above
expected parameters, build up
may exist
Process media build up on
components
Operation of valve may scratch
components. If high torque exists
after initial operation, build up
may be causing further damage
to the valve
Valve not operated
for long time and
Valve will not operate
with standard torque
Valve should be repaired
immediately, as if galling causes
the valve to seize, it is difficult to
repair.
Galling may exist
Additionally, care should be
taken to try and identify source of
galling. Potential actuation
misalignment, side loading,
foreign debris, water hammer, or
other factors may need to be
addressed before replacement.
10 Returns and Disposal
10.1
Returns
The product/system shall be emptied, cleaned, and preserved before returning the equipment
to the manufacturer. The manufacturer will only open the returned equipment if the
contamination declaration is present.
10.2
Disposal and recycling
At the end of the equipment service life, the relevant materials and parts should be recycled or
disposed of using local environmental regulation methods. If the product contains substances
which are harmful to the environment, then the removal or disposal of the equipment must be in
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G4XZ Sleeveline® Plug Valve User Instructions
accordance with local/regional regulations. This includes any liquid and/or gas in the “seal
system” or utility.
Refer to Safety Data Sheets and make sure that hazardous substances or toxic fluids are
disposed of safely and that the correct personal protective equipment is used. All activities
involving hazardous substances or toxic fluids must be in compliance with published safety
standards.
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G4XZ Sleeveline® Plug Valve User Instructions
Annex A: Declaration of Conformity
If the product/system is being sold into a country which requires a Declaration of Conformity (DoC), an
example of each DoC for the subject product/system must be included in this Annex.
(For additional information on regulatory compliance refer to CORP-ENG-0004.)
Below is an example of Declaration of Conformity for the product/system.
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G4X Sleeveline® Plug Valve User Instructions
Flowserve factory contacts:
Flowserve, Cookeville Valve Operations
1978 Foreman Drive
Cookeville, TN 38501
1-931-432-4021
www.flowserve.com
FLOWSERVE REGIONAL SALES OFFICES:
United States
Flowserve
1978 Foreman Drive
Cookeville, TN 38501
USA
Phone: 1 931 432-4021
Germany
Flowserve (Ahaus) GmbH
Von Braun Strasse 19 a D-48683
Ahaus Germany
Phone: +49 2561 686-0
India
Flowserve India Controls Pvt. Ltd.
B-8, MMDA Industrial Area,
Maraimalai Nagar, Tamil Nadu
India 603 0209
Phone: +91 44 27452323
Local Flowserve representative:
(Insert local Flowserve representative information in the text box)
Delete text in the box if not needed
To find your local Flowserve representative use the Sales Support Locator
System found at www.flowserve.com
Singapore
Flowserve Pte. Ltd.
12 Tuas Avenue 20
Republic of Singapore 638824
Singapore
Phone: + 65 6879 8900
Flowserve Corporation has established industry leadership in the design and manufacture of its products. When
properly selected, this Flowserve product is designed to perform its intended function safely during its useful life.
However, the purchaser or user of Flowserve products should be aware that Flowserve product might be used
in numerous application under a wide variety of industrial service conditions. Although Flowserve can (and
often does) provide general guidelines, it cannot provide specific data and warnings for all possible
applications. The purchaser/user should read and understand the User Instructions: Installation Operation
Maintenance included with the product, and train its employees and contractors in the safe use of Flowserve
products in connection with its application
While the information and specifications contained in this literature are believed to be accurate, they are
supplied for informative purpose only and should not be considered certified or as a guaranteed of satisfactory
results by reliance thereon. Nothing contained herein is to be construed as a warranty or guarantee, express
or implied, regarding any matter with respect to the product. Because Flowserve is continually improving and
upgrading its product design, the specifications, dimensions and information contained herein are subject to
change without notice. Should any question arise concerning these provisions, the purchaser/user should
contact Flowserve Corporation at any one of its worldwide operations or offices.
© 2017 Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation
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